Method of producing roof panelling with an integrated lighting system and the panelling thus obtained

ABSTRACT

The procedure consists in incorporating in the actual process of conforming a roof lining, determined by the securing to each other of a previously conformed lining support and the positioning and securing thereon of a coating, of one or more electroluminescent strips which will constitute a lighting system of the roof lining, which electroluminescent strips are integrated between such lining support and coating, each of them with a ribbon cable and a connector which are made to pass through a hole of the support of the lining and is finished in a connector, which is hidden by the rear face of the actual lining for its connection to the power supply of the roof of the vehicle in which the lining is applied.

BACKGROUND OF THE INVENTION

The present invention relates to a procedure for obtaining a rooflining/paneling with integrated lighting system, the fundamentalcharacteristic of which is that in the actual process of forming thelining, applicable with its coating on the roof of vehicles, itincorporates a lighting system based on electroluminescent light strips,defining a single assembly for its definitive installation on the roofof a vehicle without the necessity of having to mount the lightingsystem independently, since it is integrated in the lining itself.

The roof lining for vehicles is likewise an object of the invention,this lining being obtained by way of the procedure of the invention,which lining incorporates a lighting system constituted by one orseveral electroluminescent strips, each one of them with itscorresponding ribbon cable and connector for the supply of electricpower to this strip or these strips and a connector for the connectionto the general roof wiring system.

At the present time, some roof linings are known which incorporatedifferent accessories such as loudspeakers, head airbags, etc., theirpurpose being to increase the added value of the roof lining,incorporating therein different accessories which typically constituteelements independent of the lining.

Regarding the accessories which constitute the interior lighting systemsof a motor vehicle, these accessories are presently constituted byassemblies of pieces independent of the roof lining, and they aremounted thereon in a different and subsequent phase to that of formingthe lining.

Traditionally, the mounting of these lighting systems was carried out ina stage different to that of mounting the roof lining, although at thepresent time alternatives exist in which modular roofs are marketedwherein the mounting of some components, like those, for example,associated with the lighting system of the interior of the vehicle, iscarried out on the roof lining on the lining supplier's premises,whereby the modular assembly is subsequently mounted on the vehicle in asingle step.

In any case, the assembly of pieces which form the interior lightingsystems of vehicles corresponds to: a source of light emission; adiffuser element of the light emitted by the source; a supportingelement for the assembly; and a system of cables which feeds the lightsource with the necessary electric power.

These systems present a series of drawbacks, including:

-   -   The traditional sources of light emit heat to the consequent        detriment of user comfort, as well as of the life of other        components in the vehicle which can be mounted near to them.    -   The traditional light sources produce very localized lighting        creating areas of shadow inside the compartment, that is, they        cannot be used as ambient lighting which produces a general or        more diffuse illumination of the compartment without it being        very harsh. Nor is it possible to resolve this problem of        lighting by increasing the number of points of light, due to the        aforementioned problem of heat emission.    -   The light intensity cannot be varied as a function of the        quantity of external light or of the requirements at any given        moment.    -   The traditional lighting systems are, on occasion, a nuisance        for the drivers of other vehicles.    -   The traditional lighting systems, or at least the light        diffusers, remain visible at times when their operation is not        required, which affects the development of the complete vehicle        and the aesthetic function of the interior thereof.    -   The traditional systems require space for their location and        assembly, affecting the habitability of the interior of the        vehicle.

SUMMARY OF THE INVENTION

The present invention simultaneously resolves the functions required ofa roof lining and those required of a lighting system for the interiorof the vehicle that traditionally utilized components in lightingsystems such as the light diffuser element, support elements for thelight source, etc.

The procedure of an embodiment of the invention is based on conformingthe roof lining of a vehicle in such a way that in the same conformationprocedure the corresponding lighting system is incorporated andintegrated, the latter being determined by one or severalelectroluminescent strips, with the addition of a ribbon cable for thepower supply to the strip or strips and a connector for connection tothe general system of roof wiring.

The procedure is based on the following operative phases:

-   -   Positioning of the different layers which will form the support        of the roof lining on a press.    -   Conformation, by way of the press, of the support and the        implementation of a hole for the passage of the corresponding        power supply ribbon cable. In this same phase, in correspondence        with the corners of the support, a like number of holes are        created that serve for the centering and subsequent positioning        of the support.    -   Extraction of the lining support obtained in the above press and        positioning thereof on a supporting cradle.    -   Positioning and mounting of the electroluminescent strips on the        support of the lining located in the supporting cradle. The        securing of those electroluminescent strips on the surface of        the lining support is carried out by application of adhesive,        which could be by applying a two-sided adhesive tape previously        fixed to the electroluminescent strip, or by applying adhesive        beforehand on the corresponding surface of the lining support in        order to attach the strip on the adhesive.

This operation can be completely manual or the system of positioning theelectroluminescent strips can be automated. In the first case, areference is necessary on the lining itself, like, for example, aninsert which is implemented in the previous conforming process. In thesecond case, the actual supporting cradle will serve as reference forthe automatic positioning system.

The operation may include the positioning of the power supply ribboncable, passing the corresponding connector and a part or end of theribbon cable through the hole practiced for this purpose in the liningsupport, with the end length of the ribbon cable and of the connectorbeing arranged on the unseen face of the lining to allow theirsubsequent connection to the wiring system of the roof. Theaforementioned operation of positioning or assembly of the flatconnector and of the ribbon cable can be carried out by hand orautomatically.

For extraction of the roof lining with the electroluminescent stripsfixed thereto, with respect to the supporting cradle, the followingsteps may be performed:

-   -   Positioning of the lining support with the electroluminescent        strips on a coating press.    -   Location of the coating on the support or lining located on the        press and performing the corresponding pressing action.    -   Finally, cutting is carried out, both of the superfluous        material of the perimeter, and of those holes necessary for        housing other functions, obtaining in this way a roof lining        which has the corresponding lighting system based on        electroluminescent strips integrated therein, all capable of        being mounted correctly on the roof of a vehicle and        establishing the corresponding connection of the connector to        the power source of the vehicle roof.

The lining obtained based on the aforementioned procedure is alsocontemplated by the invention, which lining is constituted, as istraditional, by way of a support and the corresponding coating thereof,with the configuration appropriate to the vehicle in which it is to beapplied, but with the innovation of having integrated in an inseparableway the electroluminescent strip or strips which will constitute thelighting system of the roof lining.

The lining obtained offers a series of advantages with respect to thoseconventionally available, which can be summarized in the following:

1. The reduction of the manufacturing costs by performing the mountingof the lighting system in the same process of conforming the rooflining, with the consequent saving through elimination of the mountingand subsequent installation of the lighting system.

2. The elimination of such components as the light diffuser or thesupport for the source of light emission required in the traditionallighting systems.

3. The source of light emission does not produce heat, resulting ingreater user comfort and therefore allowing a larger number of lightsources distributed all over the roof.

4. The possibility of producing a uniform light inside the compartment,minimizing the number of dark areas.

5. The aesthetic aspect is enhanced both of the roof of the vehicle andof the compartment in general thereof, insofar as no element is visiblewhen the lighting system is off.

DESCRIPTION OF THE DRAWINGS

To complete the description being made to provide a better understandingof the characteristics of the invention, in accordance with a preferredexample of practical embodiment thereof, accompanying, as an integralpart of the description, is a set of drawings wherein, by way ofillustration and not restrictively, the following has been represented:

FIG. 1 is an isometric pictorial illustration showing a representationcorresponding to the first four phases of the procedure for obtaining aroof lining for vehicles with integrated lighting system;

FIG. 2 is an isometric pictorial illustration showing three followingphases of the actual process of obtaining the roof lining;

FIG. 3 is an isometric pictorial illustration showing the final phasesof an embodiment of the procedure for obtaining the roof lining;

FIG. 4 is an isometric pictorial illustration showing a representationaccording to a general perspective of a roof lining according to anembodiment of the invention, and wherein an electroluminescent strip isprovided as a lighting system integrated in the lining itself;

FIG. 5 is a plan view of the roof lining itself with the integratedlighting system formed by two electroluminescent strips arrangedlongitudinally, having eliminated from this lining the perimeter stripsin which are provided the corner holes for positioning of the support inthe corresponding presses that act in certain phases of the procedure;

FIG. 6 is a side view cross-section showing detail corresponding to theposition of an electroluminescent strip integrated in the lining, thedetail corresponding to the section A-A of FIG. 4;

FIG. 7 is a side view cross-section showing another detail of thepositioning and assembly of an electroluminescent strip integrated inthe roof lining obtained in accordance with the procedure of the presentinvention, this detail corresponding to the section represented by B-Bof FIG. 4;

FIG. 8 is a side view showing details in cross section of theelectroluminescent strip being mounted in a location on an inset of thelining support; and

FIG. 9 is a side view showing details in cross section of theelectroluminescent strip being mounted in a location on the liningsupport itself, but without insert, superimposed instead on its surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1 to 3 illustrate the procedure of obtaining roof linings with anintegrated lighting system, all in accordance with an embodiment of theinvention.

In a first phase (a), the different layers 2 are arranged on a press 1which will eventually form the lining support 3. In a following phase(b), the layers 2 are pressed to produce the lining support 3, as isshown in phase (c); the lining support 3 is then extracted from thepress 1 (phases (c) & (d).

Phase (b), in addition to forming the lining support 3, may producecorner holes 4, should they be necessary, in each of the corners of thelining support 3, as well as one or several wiring holes 5 for passingthe respective connector and power supply cable. In the event that thesubsequent positioning of the electroluminescent strips is done by hand,the support will be provided with inserts or marks which allow theoperative to have a proper reference. In the event that the positioningof the strips is automatic, the corner holes 4 are utilized in a laterphase to position the lining support 3. Those corner holes 4, althoughlocated in correspondence with the corners, belong to a perimeter stripwhich is ultimately removed from the lining support 3 in the finalcutting operation once the coating of the same has been carried out.

In an ensuing phase (e), the lining support 3 with the corner holes 4and wiring holes 5 is located on a supporting cradle 6 which, when thestrips 8 will be automatically positioned, will come with some nipples 7serving as guides for the lining support 3 by making the guide nipples 7coincide with the corner holes 4 of the support 3. When the liningsupport 3 is positioned on the supporting cradle 6, as is represented inthe detail corresponding to phase (f) of FIG. 2, the location andassembly of the electroluminescent strip or strips 8 is carried out onthe support 3, automatically or by hand, employing, in this latter case,the reference inserts made on the lining support, these strips beingfixed using an adhesive of any kind.

At this time, the flat connector 9 (FIG. 7) may be made to pass througheach of the wiring holes 5 of the support 3 so that each of the parts ofthe ribbon cable 10 to which the flat connector 9 is joined, is locatedtogether with the latter on the unseen face of the lining support 3 toallow the subsequent connection thereof to the wiring system of theroof.

In the following phases shown in (h) and (i) in FIG. 3, the coating 11is placed on the lining support 3, and all this on a new press 12. Inthat position, corresponding to phase (i) of FIG. 3, the pressing andcorresponding securing is performed, after applying an adhesive to thecoating 11 on the lining support 3. This creates the actual roof lining13, that is that formed by the support 3 and the lining 11. This rooflining 13 is extracted from that press 12 as is represented in phase (j)of FIG. 3, the roof lining 13 incorporating the lighting system based onthe electroluminescent strip or strips 8 with the cable 10 (FIG. 7)connected to them and the connector 9 for the connection to thecorresponding roof power supply, whereby the assembly can be appliedcorrectly to the roof of a vehicle without the requirement of having tocarry out subsequent assemblies as occurs conventionally in thetraditional lighting systems for vehicle roofs.

FIG. 4 shows the completed roof lining in which an electroluminescentstrip is provided as a lighting system integrated in the lining itself,and FIG. 5 shows the roof lining itself with the integrated lightingsystem formed by two electroluminescent strips arranged longitudinally,after having eliminated from this lining the perimeter strips in whichare provided the corner holes for positioning of the support in thecorresponding presses that act in certain phases of the procedure. FIG.6 illustrates detail corresponding to the position of anelectroluminescent strip integrated in the lining, the detailcorresponding to the section A-A of FIG. 4;

FIGS. 8 and 9 illustrate how the electroluminescent strip or strips 8can be located, either in an insert 14 of the actual support 3 of thelining, or on the surface thereof, that is, without inlaying.

Finally, after the phase of securing the coating 11 on the support 3,the removal is performed of the perimeter strip of the support 3 inwhich strip the holes 4 are made to obtain the definitive lining 13, asis represented in FIGS. 4 and 5.

For the purposes of promoting an understanding of the principles of theinvention, reference has been made to the preferred embodimentsillustrated in the drawings, and specific language has been used todescribe these embodiments. However, no limitation of the scope of theinvention is intended by this specific language, and the inventionshould be construed to encompass all embodiments that would normallyoccur to one of ordinary skill in the art. The present invention may bedescribed in terms of functional block components and various processingsteps. Such functional blocks may be realized by any number of hardwarecomponents configured to perform the specified functions. The particularimplementations shown and described herein are illustrative examples ofthe invention and are not intended to otherwise limit the scope of theinvention in any way.

For the sake of brevity, conventional electronics, mechanics and otherfunctional aspects of the systems (and components of the individualoperating components of the systems) may not be described in detail.Furthermore, the connecting lines, or connectors shown in the variousfigures presented are intended to represent exemplary functionalrelationships and/or physical or logical couplings between the variouselements. It should be noted that many alternative or additionalfunctional relationships, physical connections or logical connectionsmay be present in a practical device. Moreover, no item or component isessential to the practice of the invention unless the element isspecifically described as “essential” or “critical”. Numerousmodifications and adaptations will be readily apparent to those skilledin this art without departing from the spirit and scope of the presentinvention.

1. A method for creating a roof lining, comprising a lining support anda coating, with an integrated lighting system, comprising: positioning,in a press, different layers for the lining support; pressing the layersin the press, thereby producing the lining support; producing at leastone wiring hole in the lining support for passing wiring correspondingto each of one or more electroluminescent strips; when automatedelectroluminescent strip assembly is used, producing corner holes in thelining support that correspond with each of the corners of the liningsupport; extracting the lining support produced in the press;positioning the lining support on a supporting cradle, with guidenipples that, when automated electroluminescent strip assembly is used,are lodged in the corner holes of the lining support; locating orsecuring the one or more of the electroluminescent strips on the liningsupport placed on the supporting cradle; extracting the lining supportwith the one or more electroluminescent strips from the supportingcradle; mounting the lining support with the one or moreelectroluminescent strips on another press jointly with a coating; andpressing an assembly formed by the lining support and the coating in thepress, obtaining a roof lining with the electroluminescent stripsintegrated therein.
 2. The method according to claim 1, furthercomprising, in the phase of locating or securing the one or moreelectroluminescent strips, passing a connector located on an end of aribbon cable through the at least one wiring hole and connecting another end of the ribbon cable to the at least one electroluminescentstrip, a length of the ribbon cable and the connector being located onthe rear face of the lining support.
 3. A roof lining for vehicles,comprising: a lining support comprising a wiring hole; a coating thatcovers the lining support; one or more electroluminescent stripsintegrated in the roof lining, the one or more electroluminescent stripsbeing located between the support of the lining and the coating, eitheron a surface of the support or on an insert of the support; and a ribboncable comprising a connector, the connector being located on a rear faceof the lining support and configured to connect to a power supply of aroof of a vehicle to which it is applied, the ribbon cable passingthrough the wiring hole located proximate to the connector andconnecting with the one or more electroluminescent strips.